The variable geometry turbocharger and the exhaust gas recirculation system are intimately related, with overlapping trouble codes. Depending upon its J 1587 addendum, flash code 48 translates as low air, fuel, or EGR pressure, or as low EGR, turbocharger inlet (TCI), or turbocharger outlet (TCO) temperature. A very low level of fuel in the tank or restrictions in the fuel supply lines generally account for loss of fuel pressure. EGR pressure is sensed upstream of the turbocharger. Consequently, low EGR pressure comes about because of leaks in exhaust tubing going to the turbocharger or because the EGR valve sticks open to pass more than the normal volume of exhaust gases.

EGR, TCI, or TCO temperatures are influenced by the heat content of the exhaust gases mixing with incoming air. Abnormally low temperatures result from exhaust leaks in the EGR cooler or inlet piping, or from failure of the EGR valve to open sufficiently.

Code 49 signals high TCI or TCO temperatures, which can be traced to a clogged air filter, excessive exhaust backpressure, or to the EGR valve. If the EGR valve were to stick open, the higher-than-normal input of exhaust gas would be registered as an increase in turbo temperature.

Fig. 6-28 illustrates the VGT turbo, EGR valve (7) and the tube-and-shell EGR cooler (1), which is distinguished from the earlier tube-and-fin type by its rounded contours. The newer, more efficient cooler can be retrofitted to earlier Series 60 engines with kit PN 23533985, an operation that calls for reflashing the computer on DDEC IV engines built before 06R0755298. The hydraulic EGR unit must be extracted from the original cooler and pressed into the replacement part. Kent-Moore supplies special tools for these operations, although press fixtures and a suitable extractor are not difficult to fabricate.

The EGR Delta-P sensor, which measures the pressure drop across the EGR valve, has also been revised. To install the replacement sensor kit PN 23532364, the technician must open the wiring harness, snip off the original Delta-P sensor connector, splice in additional wiring, and reassign pin functions. As originally wired, pin 1 supplied voltage, pin 2 went to ground, and pin 3 carried signal voltage. Under the new scheme, pin 1 is ground, 2 signal, and 3 supply.